Allen-Bradley Open-loop Velocity Control Module User Manual (Cat. No. 1746-QV)
Important User Information Because of the variety of uses for the products described in this publication, those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements, including any applicable laws, regulations, codes and standards. The illustrations, charts, sample programs and layout examples shown in this guide are intended solely for purposes of example. Since there are many variables and requirements associated with any particular installation, Allen-Bradley does not assume responsibility or liability (to include intellectual property liability) for actual use based upon the examples shown in this publication. Allen-Bradley publication SGI-1.1, Safety Guidelines for the Application, Installation, and Maintenance of Solid-State Control (available from your local Allen-Bradley office), describes some important differences between solid-state equipment and electromechanical devices that should be taken into consideration when applying products such as those described in this publication. Reproduction of the contents of this copyrighted publication, in whole or in part, without written permission of Allen-Bradley Company, Inc., is prohibited. Throughout this manual we use notes to make you aware of safety considerations:! ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage or economic loss. Attention statements help you to: identify a hazard avoid the hazard recognize the consequences Important: Identifies information that is critical for successful application and understanding of the product. SLC is a trademark of Allen-Bradley Company, Inc. PKZIP and PKUNZIP are registered trademarks of PKWARE Inc.
Manual Changes (Series A/D) Changes to this revision of the manual include these additions: Considerations for Selecting the 15V dc Power Supply (chapter 4) Other Design Considerations (chapter 4) Testing for Proper System Operation (chapter 5) Power Supply Loading Specifications (appendix A) Publication 1746-6.18 April 1998
toc ii Summary of Changes Notes: Publication 1746-6.18 April 1998
Table of Contents System Overview................................ 1 1 Chapter Objectives.................................. 1 1 What Is the 1746-QV Module?.......................... 1 1 What Is an SLC-500 System?.......................... 1 1 Why Use This System?............................... 1 2 How Does It Work?.................................. 1 2 What Are Typical Applications?.......................... 1 2 Quick Start..................................... 2 1 Procedure......................................... 2 1 Setting Up the Software........................... 3 1 Chapter Objectives.................................. 3 1 Obtaining the Ladder Program Electronically from BBS or the Internet................................ 3 1 About the Rockwell Bulletin Board System (BBS)............ 3 1 To Access BBS:.................................... 3 1 To Access the Internet:............................... 3 2 Configuring Your SLC Processor, Off-line.................. 3 2 Modify N Files in Your SLC Processor, Off-line.............. 3 4 Output Image Table with Profile Data..................... 3 4 General Conventions for Profiles........................ 3 5 Profile Operation.................................... 3 5 Setting Up the Hardware.......................... 4 1 Chapter Objectives.................................. 4 1 Connect the LDT to Module Inputs....................... 4 1 Connect Module Outputs to Output Devices................. 4 2 Minimizing Interference from Radiated Electrical Noise......... 4 2 Considerations for the 15V dc Supply................... 4 3 Selection of the 15V dc Power Supply.................. 4 3 Application of the 15V dc Power Supply................. 4 4 Other Design Considerations........................... 4 4
ii Table of Contents Operating the Module for the First Time............... 5 1 Chapter Objectives.................................. 5 1 Power Up the System................................ 5 1 Check Wiring and Grounding.......................... 5 1 Get Ready to Move the Ram........................... 5 2 Move the Ram..................................... 5 2 Jog the Ram to the Reference Position................... 5 3 Test for Proper System Operation........................ 5 4 Troubleshoot Possible Problems......................... 5 4 Using Status Bits for Errors Detected by the Module.......... 5 4 Troubleshooting Table............................... 5 5 Conditions That Control Module Outputs.................. 5 5 Module Specifications............................ A 1 Electrical Specifications............................... A 1 Physical Specifications............................... A 1 Environmental Specifications........................... A 1 Ladder Program................................. B 1 SLC Processor Files............................. C 1 Input Image Table................................... C 1 G File............................................ C 2 Output Image Table.................................. C 2
Chapter Objectives This chapter presents a conceptual overview of how you use the 1746-QV module in an application. What Is the 1746-QV Module? The 1746-QV module is part of an SLC-based open-loop control system for controlling the speed and placement of an hydraulic ram. The module accepts an input from a linear displacement transducer (LDT) and motion profiles that you program into the SLC processor, and varies its output in the range of 10V dc. The SLC processor sends to the module a pair of extend and retract profiles that define when to accelerate or decelerate hydraulic motion. What Is an SLC-500 System? The Allen-Bradley Small Logic Controller (SLC) system is a programmable control system with an SLC processor, I/O chassis containing analog, digital, and/or special-purpose modules, and a power supply. The 1746-QV module interfaces your hydraulic ram and position-monitoring device (LDT) to the ladder sequence in your SLC processor. The system can be illustrated as follows: Power Supply SLC-500 Processor HYDRAULIC RUN FAULT LDT/ 10V DC 1746-QV module Analog Output 10v dc Proportional Amplifier Position Input from LDT Piston-type Hydraulic Cylinder and Linear Displacement Transducer (LDT) Proportional Valve Axis Motion
1 2 System Overview Why Use This System? Because you can change the speed of the hydraulic ram with extend and retract profiles and store additional profiles (recipes) in data table integer (N) files, this control system has these benefits: reduced cycle time you can increase ram speed for faster operation reduced or eliminated pressure spikes and water-hammering for smoother operation and less wear and tear on the machine you can profile accelerations and decelerations of the hydraulic ram energy savings you can match the speed of the hydraulic pump to the force that you need faster new-part change-over you can store your setups and minimize mechanical re-adjustments between parts How Does It Work? The 1746-QV module executes the extend and retract profiles that you load to control the motion of the hydraulic ram. You can program up to seven different voltages over the length of travel in both the extend and retract directions to control how the ram accelerates or decelerates. Voltage 2 Extend Direction 3 4 5 6 Voltage 2 Retract Direction 4 3 5 6 1 Segments 7 1 Segments 7 LDT Head Position LDT Head Position Each position setpoint triggers a corresponding voltage output in the range of 10V to +10V dc that translates into speed. The LDT provides high-speed position updates to the module for consistent and repeatable motion. What Are Typical Applications? Use the 1746-QV module in an SLC-based system for low-cost control of: hydraulic machinery simple (non-cnc) hydraulic presses diecasting machinery welder placement pneumatic actuators for clamping or placement In addition, the module is designed to support standard proportional amplifiers and retrofit into most existing hydraulic systems.
Procedure Use this chapter as an abbreviated procedure for getting the 1746-QV module into operation or as an overview if you need more information. 1. Load Ladder Logic into Your Computer Chapter 3 Obtain the ladder program (appendix B) from Rockwell Software Bulletin Board (BBS) or the Internet. From BBS: (216) 646-ROCK (-7625). If a new user, follow prompts to register. Log in. Look for 1746QV in the Allen-Bradley Products Library. The manual is in Word format. Download it into a hard drive subdirectory and decompress it with PKUNZIP available on BBS. The ladder program, VELMOD, is SLC500 code (65 Kbyte). Download it into a hard drive subdirectory where your programming software looks for files. From Internet: webpage http://www.ab.com If a new user, click Join Now and follow prompts to register. Log in. Search for QV: on homepage, click Search Our Site, insert QV in window, and click search button. The manual is PDF format and requires Adobe Acrobat viewer. The ladder program is PDF format and must be entered manually. 2. Set Up Your Software Chapter 3 Configure the SLC Processor and I/O with your programming software. Enter the following: a) processor type, b) module I/O-chassis slot, c) module ID (13115), d) G-file size (7 words), and e) G-file configuration values from the ladder program (appendix B). Modify N files for the profile found in the ladder program (appendix B) to suite your application. 3. Connect the LDT to the Module s Input Terminal Block Chapter 4 The following are connections between the 1746-QV module and typical LDTs such as Temposonics, Balluff, Santest, and Gemco. 1746-QV Module Input Terminal Block 8 7 6 5 4 3 2 1 (+) Gate Out ( ) Gate Out ( ) Interrogate (+) Interrogate Shield/Frame 15V dc PS PS Common +15v dc PS Temposonics II, RPM or DPM PS Interrogate Common (+) 1 (+) ( ) Frame 9 7 5 3 2 GND 10 8 6 4 ( ) ( ) (+) Gate Out 15V dc PS Balluff BTL-2-L2 & -2-M2 Interrogate ( ) Gate Out ( ) Gate Out (+) 2 5 4 3 8 ( ) 1 7 (+) 6 Interrogate (+) 15V PS dc PS Common The views are looking at the connector on the LDT head. Santest GYRP & GYRG Gemco Quick-Stick II 951VP w/pwm Output NC +15V PS B BLK PS Common dc PS Common C RED +15V dc PS 2 K GRY + Interrogate 1 3 E BRN Sq Wave Out* F BLU +Sq Wave Out* 4 (+) A WHT Interrogate 5 7 G, D, H RS232RXD Gate 6 ( ) J PUR 2nd PS COM Gate Out (+) Out ( ) *951RS has pulse trigger Interrogate 1746-QV Function Temposonics II Balluff Santest Gemco Quick- Input Pin # RPM or DPM BTL-2-L2 & -M2 GYRP/GYRG Stick 951VP/RS 8 (+) Gate Out 4 Pink 2 Gray (note 1) pin 5 F Blue (note 1) 7 ( ) Gate Out 3 Gray 5 Green (note 1) pin 7 E Brown (note 1) 6 ( ) Interrogate 10 Green 3 Pink pin 6 A White 5 (+) Interrogate 9 Yellow 1 Yellow pin 4 K Gray 4 Shield/Frame n/a n/a n/a n/a 3 15V dc PS 6 Blue 8 White n/a n/a 2 PS Common 1 White 6 Blue pin 3 B Black 1 +15V dc PS 5 Red 7 Brown pin 1 C Red (+) and ( ) wires of same function should be a twisted pair within the cable. Note 1: In the table, we use the term gate out for pulse trigger or square wave (Gemco) and start/stop (Balluff -M2) LDT signals.
2 2 Quick Start 4. Connect Module Output Terminals to Output Devices With Correct Bonding Chapter 4 Important: Connect the shield of the amplifier output cable to a 0V connection in the amplifier. 1746-QV Output Terminal Block 2 1 Analog Output ( 10v dc) Servo Amplifier (Proportional) (+) Diff. ( ) Input 0V Outputs A to valves B +24V dc PS 0V dc PS Do NOT connect output shields to earth ground To solenoid A To solenoid B 5. Minimize Interference from Electrical Noise with Correct Shielding and Grounding Chapter 4 Important: Connect PS output commons togerther. Connect the following to earth ground: a) cable shields (except for amplifier outputs) at one end only, b) input terminal 4, c) case grounds of PS and amplifier, e) LDT flange. LDT Power LDT Signals 1746-QV Module Input 1 2 3 5-8 4 2 Output 1 earth ground 15V PS (+) (C) ( ) Belden 8770 Analog Output Belden 8761 Case GND Piston-type Hydraulic Cylinder and Linear Displacement Transducer (LDT) Servo Proportional Amplifier 0V Valves 24V PS Important: For correct bonding, connect PS output commons together and isolate from earth ground. ( ) (+) Case GND Belden 8761 Case GND Cable Note Cable Note: Use cable recommended by the LDT and amplifier manufacturer. Cable Note LDT and Hydraulic Ram 6. Operate the Module for the First time Chapter 5 After loading profiles with the ladder program (step 1), alternately run the extend profile (O:e.0/0 = 0-to-1), then the retract profile (O:e.0/1 = 0-to-1). Modify the profile to reach the preset reference, and set it. Important: If motion is reversed: for a 10V dc output, change the sign ( ) of all extend/retract voltage values; or for a +10V output, energize the other solenoid on the directional valve (with ladder logic). To do this: Enter decimal: at address: load all profiles 1 N7:40 set preset reference to zero 8 N7:50 clear errors 16 N7:50 read current position read, only N7:61 run an extend profile 1 N7:50 run a retract profile 2 N7:50
Chapter Objectives Obtaining the Ladder Program Electronically from BBS or the Internet This chapter helps you do the following: Obtain the ladder program electronically Configure your SLC processor off-line Modify N files in your SLC processor, off-line General conventions for profiles Profile operation You can obtain ladder logic electronically and download it to your SLC processor conveniently without the worry of data-entry errors. About the Rockwell Bulletin Board System (BBS) You can access the Rockwell Software Bulletin Board System (BBS) by modem. Anyone is welcome. The BBS provides utilities, examples, and technical information on Rockwell Software products and on selected Allen-Bradley products. new users may: send and receive messages download General Access files upload files for review by technical support specialists verified customers may: search for new and existing files download files such as utilities, example programs, tech info access software bulletins subscribers to tech bulletins, DataDisc CD-ROM may: download tech bulletins of the Tech Bulletin Subscription series User accounts are automatically generated online. We use our product data base to verify BBS accounts at your initial log-in, and we adjust your security level according to your support status. Should your registration information change, you can update your account from the Configure System Defaults menu. To Access BBS: 1. Set your modem to no parity, 8 data bits, and 1 stop bit. 2. Dial (216) 646-ROCK (-7625). 3. Follow prompts to log in. New users must create a new account. 4. Look for 1746QV in the Allen-Bradley Products Library. The manual is formatted in Microsoft Word and compressed with PKZIP. The ladder program, VELMOD, is SLC code.
3 2 Setting Up the Software 5. Download ladder program VELMOD (65 Kbyte SLC code) into the subdirectory on your hard drive where your programming software looks for files. With RSLogix: C:\... RSLogix 500 English\Project. 6. Download the ladder program to your SLC processor. 7. Download the manual into a hard drive subdirectory. You must decompress the Word version with PKUNZIP available on BBS. To Access the Internet: 1. Access the Allen-Bradley webpage at: 2. To access the member area, you must log in. If you do NOT have an account, click Join Now and follow the prompts to register. 3. Search for QV: on homepage, click Search Our Site, insert QV into the window, and click Search button. The manual is PDF format and requires Adobe Acrobat viewer. The ladder program is PDF format and must be entered manually. Configuring Your SLC Processor, Off-line This procedure assumes you are using RSLogix500 Programming Software, version 2.10 or later. For other software, the procedure may vary. 1. Open your 1746-QV project, VELMOD. 2. Configure the type of SLC processor. To do this: A. Open the file, Controller Properties. B. Select the SLC processor type and click OK. 3. Configure the rack size, module slot, and module ID: A. Open the file, I/O Configuration. B. Select the rack size. C. Highlight the slot number for the module. D. From the list of modules, scroll to 1746-QV and double click. If the module is not listed: Scroll to Other and double-click. Enter the module s ID (13115) and double-click. 4. Size the G file: A. Highlight 1746-QV (or 13115 if module was not listed). B. Click [Adv Config]. C. In the dialog box, enter a G-file length of 7. D. Press [Edit G Data].
Setting Up the Software 3 3 5. Enter values in the G file: If the module was listed: You get the G file Setup screen. Enter data from the table, below. If the module was not listed (you entered the ID): You get the following display, shown in decimal radix. Enter a value in each word as shown, next. G file display for unlisted module (shown in decimal radix): Ge:0 2056 0 0 0 0 0 0 Enter a value at each G-file word address and press [ENTER]. Then cursor to the next word address and repeat. For example: Ge:0 2056 893 730 12 1200 32768 0 We used values from the ladder logic example (appendix B). You will want to use G-file values that suit your application: Word: Function of G-file Word: Range: Description of G-file Word or Bit: Example: 0 Reserved. Do NOT use. n/a The processor stores a code for the 1746-QV module. 2056 words 1 & 2 refer to the gradient or transducer calibration value stamped on the name plate on the transducer housing. 1 LDT calibration: upper 3 digits 800-999 s/inch For example: To enter an LDT calibration of 8.9373, 893 2 LDT calibration: lower 3 digits 000-999 s/inch use decimal radix and enter 893 in word 1 and 730 in word 2. 730 3 Full-scale length (L) of LDT 2 L 160 inch Enter the length of the LDT (160 inches max). 12 4 Full-scale count (C) 2 C Lx100 Typically C = L x 100. 1200 Position Data (I:e.1) = C/(L x 100) LDT Calibration 5 Configuration Bits bits 0-12 Set to zero. 32,768 15 14 13 12-0 Equivalent Value bit 13 0 = output maintained during LDT fault while running profiles and (bit 15 = 1 0 1 0 0 +16,384 for position during SLC mode change 1 0 0 0 32,768 increases 1 1 0 0 16,384 1 = output resets for LDT fault and SLC mode change towards 0 1 1 0 +24,576 LDT head) bit 14 Type of LDT: 0 for RPM, 1 for DPM bit 15 0 = position data increases when moving away from LDT head 1 = position increases when moving toward LDT head 6 Preset Reference 32,768 to +32,767 Typically zero or home reference value. 32,767 = 327.67 inches. 0 Examples of Full-scale Count Values LDT Physical Length No. of Recirculations Resolution Full-scale Length (L) Full-scale Counts (C) from 160 to 2 1 0.01 L (160 to 2 ) L x 100 16 2 0.01 160 8000 16 4 0.01 160 4000 16 10 0.001 160 16000 Important: The module checks for invalid data such as out of range values or the setting of reserved bits 0-12. You can clear a data-entry configuration error only by re-entering a corrected value. 6. Save when done. Click OK. Click OK. Close window.
3 4 Setting Up the Software Modify N Files in Your SLC Processor, Off-line One N file may contain the initial commands, setpoints, and values for configuring the extend and retract profiles. A set of profile data for initial configuration Retract Voltages Retract Positions Extend Voltages Extend Positions Command and Setpoints >>> >>> >>> >>> Output Image Table Command and Setpoints >>> >>> >>> >>> 1746-QV Module Extend and Retract Profiles Output Image Table with Profile Data The file contains commands and data starting at the these addresses: command and position setpoints for extend #N7:0 command and voltage (velocity) values for extend #N7:10 command and position setpoints for retract #N7:20 command and voltage (velocity) values for retract #N7:30 The sample ladder program (appendix B) copies profile data into the output image table from the above locations. Word: Function of Output Image Word: Bit #: Description: (For command bits, a 0-to-1 transition enables the command) 0 Command Bits 0 Set to run an extend profile. 1 Set to run a retract profile. Enable these e bits (O:e.0/bit #) 2 Set to disable the profile. This bit over-rides bit 0 or 1. with your ladder logic, where e represents the I/O slot number. 3 Set to change the current position data to the value of the preset reference stored in Ge:6. 4 Set to clear any data-entry errors. 5 Set to define words 1-7 as programmed position setpoints for extend. 6 Set to define words 1-7 as programmed voltage values for extend. 7 Set to define words 1-7 as programmed position setpoints for retract. 8 Set to define words 1-7 as programmed voltage values for retract. 9-15 Reserved. Do NOT use. 1-7 Position Setpoint or Voltage Value n/a Important: Position setpoints are in units of 0.01 (200 = 2.00 ) within the range of 327.68 to +327.67, and voltage values in 5mV units (3005 = 3.005V) within the range of 10,000mV. The data monitor mode of your programming software displays the data files shown below (with values from the ladder program). Important: Modify these values to suit the preset reference chosen for the G file and/or to match the LDT length. Extend Positions: N7:0 32 45 50 200 300 400 425 500 0 0 Extend Velocities: N7:10 64 3000 3750 4000 4000 4000 4000 4000 0 0 Retract Positions: N7:20 128 45 50 200 300 400 425 500 0 0 Retract Velocities: N7:30 256 5000 6000 6000 3000 1000 50 25 0 0
Setting Up the Software 3 5 General Conventions for Profiles Consider the following when you set up your profiles: Extend and retract define the profile with respect to the LDT head: extend is always away from the head, retract is always towards it Position data changes direction depending on how you set configuration bit Ge:0/15 for LDT motion: 0 = position data increases when moving away from LDT head 1 = position data increases when moving towards LDT head Each position setpoint triggers from the absolute position data (I:e.1) as modified by the preset reference. Position setpoints are in units of 0.01. For example, enter 2 as 200. If you enter position setpoints in random order, the module places them in ascending order (P1 = lowest and P7 = highest) with their associated voltage value. Speed segments are defined increasing from the LDT head, regardless of position data direction. Speeds are reported in the input image table words 2-7 (I:e.2-I:e.7) for the previous profile (extend speeds reported during the next retract profile and vice versa) Voltage values (for speed) are in the range of 10,000mV in multiples of 5mV. For example, enter 5.005V as 5005. Important: Enter voltage values in multiples of 5mV or the module will fault, causing you to correct and re-download the profile. Voltage values are cleared when you re-program position setpoints. The profile is cleared when the module loses power or when you change the value of any G-file configuration word. Important: Your application may require different position setpoints and voltage values. Your profiles must be consistent with the physical parameters of the LDT and G file to guard against damaging hardware. Profile Operation In general: For relatively faster and smoother motion, use two speed segments for acceleration and five speed segments for deceleration. Adjust the ramp rate on the proportional amplifier for the smoothest operation. Initially, start with the ramp disabled (fastest ramp rate). You may compensate for deadband or valve overlap by specifying a voltage value greater than or equal to the valve s bias current. Profile operation depends on how the module reports position data. With the data-direction bit (Ge:0/15), you select whether: position data increasing towards the LDT head (Ge:0/15 = 1) position data increasing away from the LDT head (Ge:0/15 = 0)
3 6 Setting Up the Software For Position Data Increasing Towards LDT Head (Ge:0/15 = 1) Voltage Output = 0 past position 1 Position V1 Speed Segment 6 P1 V2 V3 V4 Speed Segment 5 P2 Speed Segment 4 P3 Speed Segment 3 P4 V5 V6 V7 Speed Segment 2 P5 Speed Segment 1 P6 P7 LDT head Starting with the ram between P7 and the LDT head (open position), running the extend profile results in V7 applied to the output. As the ram passes below P7, V6 is applied to the output, etc. If the ram passes below P1, the output is forced to 0V dc, and the profile is disabled. You must load new data to operate the profile. Placement operations require two segments. For example, if P2 = 6.07, V2 = 1.500V, P1 = 0.00 (or a value less than P2), and V1 = 1.500V, then the module will place the ram in the vicinity of P2 (between 6.02 and 6.12). The negative voltage V1 causes motion to reverse or stop. To see this, enter the example values for P2, V2, P1, and V1 in the previous diagram. Position Data Increases from LDT Head (Ge:0/15 = 0) Voltage Output = 0 past position 7 V7 Speed Segment 6 V6 V5 V4 Speed Segment 5 Speed Segment 4 Speed Segment 3 V3 V2 V1 Speed Segment 2 Speed Segment 1 LDT Position P7 P6 P5 P4 P3 P2 P1 head Starting with the ram between P1 and the LDT head (open position), running the extend profile results in V1 applied to the output. As the ram passes P1 towards P2, V2 is applied to the output, etc. If the ram passes P7, the output is forced to 0V dc, and the extend profile is disabled. You must load new data to operate the profile.
Chapter Objectives This chapter helps you install the hardware with these tasks: connect the LDT to module input terminals connect module output terminals to output devices minimize interference from radiated electrical noise considerations for the 15V dc power supply other design considerations Connect the LDT to Module Inputs We assume that you will use one of the following types of LDT: Temposonics II: RPM TTSRxxxxxxR, or DPM TTSRxxxxxxDExxx Balluff: BTL-2-L2, or BTL-2-M2 Santest: GYRP, or GYRG Gemco Quick-Stick II: 951VP, or 951 RS We illustrate typical connections between the 1746-QV module and these types of LDTs. (There are other suppliers with compatible LDTs.) 1746-QV Module Input Terminal Block 8 7 6 5 4 3 2 1 (+) Gate Out ( ) Gate Out ( ) Interrogate (+) Interrogate Shield/Frame 15V dc PS PS Common +15v dc PS Temposonics II, Balluff RPM or DPM BTL-2-L2 & -2-M2 PS Interrogate ( ) Gate Out ( ) NC Gate Out (+) +15V Interrogate 2 2 Common dc PS (+) 1 (+) ( ) 5 4 1 3 Frame 9 7 5 3 2 GND 3 8 ( ) 1 4 (+) 10 8 6 4 ( ) ( ) (+) 7 (+) 6 5 7 Gate Out Interrogate (+) Out (+) Gate 6 ( ) 15V PS 15V dc PS dc PS Common Interrogate The views are looking at the connector on the LDT head. Santest GYRP & GYRG PS Common Gate Out ( ) Gemco Quick-Stick II 951VP w/pwm Output B BLK PS Common C RED +15V dc PS K GRY + Interrogate E BRN Sq Wave Out* F BLU +Sq Wave Out* A WHT Interrogate G, D, H RS232RXD J PUR 2nd PS COM *951RS has pulse trigger Connect each 1746-QV input pin # to the corresponding LDT pin #. 1746-QV Input Pin # Function Temposonics II RPM or DPM Balluff BTL-2-L2 & -M2 Santest GYRP/GYRG Gemco Quick- Stick 951VP/RS 8 (+) Gate Out 4 Pink 2 Gray (note 1) pin 5 F Blue (note 1) 7 ( ) Gate Out 3 Gray 5 Green (note 1) pin 7 E Brown (note 1) 6 ( ) Interrogate 10 Green 3 Pink pin 6 A White 5 (+) Interrogate 9 Yellow 1 Yellow pin 4 K Gray 4 Shield/Frame n/a n/a n/a n/a 3 15V dc PS 6 Blue 8 White n/a n/a 2 PS Common 1 White 6 Blue pin 3 B Black 1 +15V dc PS 5 Red 7 Brown pin 1 C Red (+) and ( ) wires of the same function should be a twisted pair within the cable. Note 1: In the table, we use the term gate out for pulse trigger or square wave (Gemco) and start/stop (Balluff -M2) LDT signals.
4 2 Setting Up the Hardware Connect Module Outputs to Output Devices Module outputs connect to a separate 2-conductor output terminal block located beneath the input terminal block. 1746-QV Output Terminal Block 2 1 +24V dc PS 0V dc PS Analog Output ( 10v dc) Servo Amplifier (Proportional) (+) Diff. ( ) Input 0V Outputs A to valves B Important: Ground the shield of the amplifier output cable to a 0V connection in the amplifier. Do not connect the shield to earth ground. To solenoid A To solenoid B Note: Follow manufacturer recommendations for shielding the output cables of the proportional amplifier. Typically, pulse-width modulated outputs radiate electrical noise originating from the +24V dc power supply, so isolate the shields of the amplifier output cable to a 0V dc connection inside the proportional amplifier. You have a choice of three configurations to match your hydraulics: proportional amplifier with ramp and proportional valve servo amplifier with ramp and variable-volume pump Allen-Bradley 1305 Drive and hydraulic pump You may use either of the following output voltage ranges: 0-10V dc for the Allen-Bradley 1305 Drive or variable-volume pump 10 to +10V dc for the proportional amplifier and proportional valve Minimizing Interference from Radiated Electrical Noise Important: Signals in this type of control system are very susceptible to radiated electrical noise. The module is designed to set the loss-ofsensor bit I:e.0/8 and the LDT-error bit I:e.0/0 when it detects position values that are lost or corrupted by electrical noise. Connect module output terminals to output devices with correct bonding: connect power supply output commons together electrically isolate power supply output commons from earth ground use bond wires that are equal in size to signal wires Minimize interference from radiated electrical noise with correct shielding and grounding: connect all of the following to earth ground: LDT flange, frame, and machine I/O chassis protective ground AC ground cable shields at one end only, preferably with 3/8 braid wire (for analog output, 15V dc PS, 24V dc PS, and LDT) terminal 4 of the input terminal block
Setting Up the Hardware 4 3 run shielded cables only in low-voltage conduit place the SLC-500 processor, power supply, and I/O chassis assembly in a suitable enclosure Typical grounding and shielding for this type of control system: 1746-QV Module Input 15V Power Supply (+) (C) ( ) Case GND 24V Power Supply ( ) (+) Case GND LDT Power LDT Signals 1 2 3 5-8 4 Output earth ground Analog Output Belden 8770 Belden 8761 Belden 8761 0V Servo Proportional Amplifier Cable Note Case GND Piston-type Hydraulic Cylinder and Linear Displacement Transducer (LDT) Valves Cable Note: Use cable recommended by the LDT and amplifier manufacturer. Cable Note LDT and Hydraulic Ram Considerations for the 15V dc Supply Selection of the 15V Power Supply The positive and negative supply of some 15V dc power supplies decay at different rates when ac power is removed. The module s output will be biased, based upon the difference in voltage level between the positive and negative supply. The duration is dependent upon the magnitude of the difference and the decay rate. For these reasons, the 15V dc power supply should have or be equipped with: proper interlocks with machine operation and e-stop circuits an internal voltage-sense relay that drops the 15V (without variation in decay rates) upon loss of ac power auxiliary relay to indicate proper operation and voltage (such as loss of +15V but not 15 V dc) Power Supply Loading The module and LDT load the power supply typically as follows: Supply No Transducer No Load Transducer Only * LDT + Module: +10V dc @ 10mA LDT + Module: 10V dc @ 10mA +15V dc 86mA 128mA 141mA 128mA 15V dc 14mA 30mA 30mA 40mA *MTS Temposonics II, model T1SR0U0120R (Other LDTs will have different loading.)
4 4 Setting Up the Hardware Application of the 15V Power Supply The module uses the 15V dc power supply to drive the 10V dc valve output and to power the LDT. The module detects loss of 15V dc with its internal LDT diagnostic. The diagnostic concludes loss of 15V when it detects loss of LDT magnet. Partial failure of the 15V dc power supply may cause limited machine operation when the LDT continues to operate properly. Some LDTs will operate with its supply voltage down to 12V. If you monitor the 15V dc with SLC diagnostics, you can enable a blocking valve to lock the actuator in its last position upon detection of: e-stop power loss low voltage condition of the 15V dc supply ATTENTION: If you provide a system e-stop circuit and design the system to manage power to the SLC chassis and 15V dc supply, in all cases DO NOT connect the e-stop to ac power for power supplies. Other Design Considerations ATTENTION: We recommend using reasonable methods to assure that unintended motion does not cause machine damage or create a safety issue with personnel who will operate the machine. (Chapter 5 covers testing for proper system operation.) Use a proportional valve that does not respond to voltage spikes created by power supply operation. Shut down the hydraulic system upon loss of ac power and automatically vent pressurized fluid back to the tank. Provide ladder programming that interlocks the operation of the power supply with permissives to run the hydraulic pump. Connect a high-speed relay between the module and the valve amplifier to drop-out the valve signal upon loss of ac power.
Chapter Objectives This chapter outlines the steps for operating the module for the first time with an operating hydraulic ram. We cover these steps: power-up the system test for proper system operation troubleshoot possible problems Power Up the System Starting with module and LDT power turned off, bring the system on-line for the first time as follows (refer to I/O wiring in chapter 4): Check Wiring and Grounding 1. Disconnect the LDT connector at the head end. 2. Disconnect both of the module s input and output terminal blocks. 3. Turn ON the power supplies for the LDT and SLC processor, and check the LDT connector and module input terminal block for: pin 1 +15V dc pin 2 PS common pin 3 15V dc 4. Observe that the module s fault LED (red) is ON. 5. Verify NO continuity between pin 2 (PS commons) and pin 4 (shield/frame) on the module s input terminal block. 6. Verify NO continuity between the LDT cable shield and pin 2 (PS commons) on the module s input terminal block. 7. Verify continuity between pin 2 (PS commons) on the module s input terminal block and the output common on the 15V dc PS that powers the LDT and module. 8. Verify continuity between pin 2 (PS commons) on the module s input terminal block and the ( ) terminal on the +24V dc PS that powers the proportional amplifier. 9. Verify NO continuity between the +24V dc PS ( ) connection and earth ground. 10.Verify continuity between the shield of the amplifier output cable and pin 2 (PS commons) on the module s input terminal block. 11. Verify continuity between the cable shield (Belden 8761 or equivalent) on the +24V dc PS and earth ground.
5 2 Operating the Module Get Ready to Move the Ram 1. Turn on the +24V dc PS that powers the amplifier. 2. Turn on the hydraulic pump and null the ram for no movement. 3. Turn off all power supplies. 4. Connect the LDT cable and input terminal block. 5. Turn on all power supplies. 6. Be sure that you have loaded the extend and retract profiles into the module. 7. Observe module LEDs. The RUN LED (green) should be blinking. If not blinking, refer to troubleshooting covered last in this chapter. Module LEDs indicate the following to assist you with the procedures: This LED: Is: When the Module detects: RUN Flashing output is at 0V dc (green) ON profiles are loaded and output is active FAULT OFF no internal faults (red) Flashing an LDT fault ON an internal fault For Series A Revision A: During startup, Run LED ON and Fault LED flashing indicate outputs are at 0V dc. During profiles, Fault LED is OFF. 8. Observe that the output image table word 0 (O:e.0) is zero. If not zero, toggle the value of N7:50 from 0 to 16 to 0. Reload the profiles by entering the value of 1 into N7:40. If profiles do not reload, refer to Troubleshooting on page 5-4. 9. With the output terminal block still disconnected, run the extend profile by changing the value in N7:50 to 1. The RUN LED should change to ON. If not, refer to troubleshooting covered last. Important: Reset the value in N7:50 to 0. 10.Connect the output terminal block. Move the Ram Important: When you set an output bit with your programming terminal, the commanded action takes place immediately. 1. Run the extend profile by momentarily changing the value in N7:50 to 1, and observe the direction of ram movement in N7:61. If the ram moves in the wrong direction: If using this type of valve and signal: proportional valve with 10V input hydraulic motor or ac drive with 0-10V input Then reverse the: sign ( ) of all voltage values and load them into the module other solenoid on the directional valve (with ladder logic)
Operating the Module 5 3 2. After reversing the sign of voltages (if needed), run the extend profile again by changing the value in N7:50 to 1. Observe that the direction of ram travel is correct. Important: Reset the value in N7:50 to 0. 3. Check the position value reported in the status word, N7:61, as you run the ram to the end of its travel. If the position data is reversed, you may need to change the data-direction bit (Ge:5/15) in the G file off-line as follows: 0 = position increases while moving away from LDT head 1 = position increases while moving toward LDT head Important: You must reload profiles for either of these conditions: Changing a value in the G file. (This clears the profiles). When position data exceeds the position setpoint that is farthest from the LDT head, the profile is disabled and you must modify position setpoints and reload the profiles. 4. Verify operation of the retract profile by changing the value in N7:50 to 2. Important: Reset the value in N7:50 to 0, afterwards. Jog the Ram to the Reference Position The reference position may require that you jog the ram beyond a position defined by the profile in the ladder program (appendix B). You may jog the ram as follows: 1. Observe the current position data (in I:e.1). 2. Modify profile position setpoint(s) to permit the ram to travel to the required reference position using the current position. For example: If position data reads 100, change P1 to 1300 (length of the LDT) 3. Important: Reset the value in N7:50 to 0. Load the profiles into the module. 4. Run the extend profile by changing the value in N7:50 to 1, and jog the ram to the reference position. 5. At the reference position, the position data, I:e.1, (N7:61) will be an arbitrary value. Set the position data to the value of the preset reference by changing the value in N7:50 to 8 (N7:40 must = 0). Position data will change to preset reference (0 in this example). 6. Verify that N7:61 now reads zero at the reference position. Important: Once you establish the reference position: the module will maintain the preset reference s position data in I:e.1 all profile position setpoints will be referenced to it (until you clear Ge:6 by changing any G-file value or set another reference position. The preset reference is retained during power up.
5 4 Operating the Module Test for Proper System Operation ATTENTION: Test for proper system operation to verify that precautions to guard against unexpected motion perform as intended. (See Power Supply and Design Considerations in chapter 4) Because of the wide variety of applications for this module, we leave the procedural details to you. Look for proper system operation as you test for these conditions: controlled system startup/shutdown when turning hydraulics on/off startup/shutdown of ac to power supplies ( 15V dc, SLC chassis, and 24V dc) loss of LDT input effect of the last-state-of-output bit (G-file, word 5, bit 13) regarding one or more of the above Troubleshoot Possible Problems Using Status Bits for Errors Detected by the Module The module is designed to detect and indicate status as follows (in the input image table word I:e.0 or N7:60 in the ladder program): hardware operational faults data entry errors when entering setpoints or setting control bits acknowledgement of stored setpoints Important: To clear error bits, toggle N7:50 from 0 to 16 to 0. Bit #: Description: (for error & fault bits 0-8, status of 0 = OK, status of 1 = fault.) 0 The module sets this LDT error bit when it detects a: broken or mis-wired LDT cable faulty LDT incompatible LDT type (DPM or RPM) missing LDT magnet loss of 15V dc PS 1 Module fault, such as EEPROM error. May turn outputs OFF (fault dependent) 2 The module sets this bit when it detects any of the following invalid command bits or bit combinations in output image table word 0 (O:e.0): one or more of the reserved bits 9-15 were set bit 5 or 7 (position) was set concurrently with bit 6 or 8 (voltage) output enable bit 0 (extend) or 1 (retract) was set before loading valid profiles both output enable bits 0 (extend) and 1 (retract) were set concurrently started to run a profile after the module had flagged an LDT error (I:e.0/0) 3 You set one or more of the reserved bits 0-13 in G-file word 5 (Ge:5). 4 You entered an invalid length (word 3) or count (word 4) in the G file. 5 You entered an invalid LDT calibration (words 1 and/or 2) in the G file. 6 You entered position setpoint outside the range 32,768 to +32,767 in O:e.1-O:e.7. 7 You entered a voltage value outside the range of 10,000mV in O:e.1-O:e.7. 8 Loss of sensor. The module detected position data (in I:e.1) greater than the LDT length plus the preset reference. Clear this bit by running a profile. 9-11 Reserved. Do NOT use.
Operating the Module 5 5 Bit #: Description: (for error & fault bits 0-8, status of 0 = OK, status of 1 = fault.) 12 The module sets this bit after it stores retract position setpoints or voltage values, or when retract profile is active. It remains set until another operation is performed. 13 The module sets this bit after it stores your position setpoints. It resets it after you reset the program position bit (O:e.0/5 or O:e.0/7) 14 The module sets this bit after it stores your voltage values. It resets it after you reset the program voltage bit (O:e.0/6 or O:e.0/8) 15 The module sets this bit when it detects the profile is active (output is applied). Troubleshooting Table If you observe this condition: Try this solution: Refer to this part of the manual: Sensor signal (N7:61) has wrong sign ( ). After download, sensor values do not match values in N7:61 before download. Module rejects ect pre-set et reference when N7:50 is toggled from 0 to 8 to 0. 1. Change direction bit (Ge:5/15) and re download. a) Enter values in G file, page 3-3. b) Move the Ram, step 3, page 5-3. 2. Calibrate the sensor at opposite end of cylinder. Re-do Jog Ram to Reference, pg 5-3. After axis calibration (preset ref = set, and N7:50 = 8), none you must upload and save SLC data files in the PC. 1. Pre-set Ref in G file must be within profile range. Enter values in G file, page 3-3. 2. N7:40 must = 0 when setting N7:50 = 8. Re-do Jog Ram to Reference, pg 5-3. Profiles will not load into the module. 1. Each profile setpoint must be within sensor s range. Verify full-scale count in Ge:4, page 3-3. Unable to initiate extend/retract profiles. 2. Clear any errors by toggling N7:50 (0 to 16 to 0) Prior to step 8 in Get Ready to Move Ram. 3. N7:40 must = 0 when setting pre-set reference Jog Ram to Reference, step 5, pg 5-3. with N7:50 = 8. Write ladder rung for extend profile, another for retract. none Each must include appropriate permissives to enable a MOV instruction with Source (1 = extend, 2 = retract) and Destination = N7:50. Conditions That Control Module Outputs The module is designed to control its outputs as follows: The module is designed to: apply profile voltages to the output retain its outputs in last state turn OFF its outputs When these conditions are satisfied: all of the following: valid extend and retract profiles are stored in the module the stop profile bit (O:e.0/2) is reset. a run profile bit (O:e.0/0 or O:e.0/1) is set any of the following: loss of backplane power ( 15V dc PS remains applied) loss of sensor (LDT) SLC mode change or LDT fault (G:e:0/13 = 0) any of the following: LDT position exceeded the setpoint farthest from LDT head loss of 15V dc PS the disable output bit (O:e.0/2) is set SLC mode change or LDT fault (G:e:0/13 = 1)
5 6 Operating the Module Notes:
Electrical Specifications This appendix lists the specifications for the 1746-QV Open-loop Velocity Control Module. 215 ma at 5V dc (from backplane) Power Requirements 400 ma at +15V dc and 295 ma at 15V dc (from independent PS, typical but LDT dependent) I/O Chassis Location Any I/O-chassis slot except slot 0 1500V ac optical isolation Isolation between LDT input and backplane Interrogate Gate LDT Inputs 15V dc PS PS Common Shield/Frame Compatible LDT Input Devices Module Range and Resolution Analog Output Accuracy of Voltage Output Module Update Time Linear Displacement Transducer such as: Balluff BTL-2-L2 or -M2 Gemco Quick-Stick II Santest GYRP or GYRG Temposonics II with DPM or RPM 160 inches 0.01 inch 0-10V dc @ 250 ma or 10 to +10V dc @ 250 ma Within 1% of its programmed value 2 ms Physical Specifications Run ON Profile running, Output active (green): Flashing Output at 0V dc LED Indicators Fault OFF Module OK (red): Flashing LDT fault ON Module fault Module ID Code 13115 Maximum Wire Size Two 18 AWG wires per terminal on terminal block Environmental Specifications Operating Temperature Storage Temperature Relative Humidity Agency Certification (when marked on product or package) 0 C to 60 C (32 F to 140 F) 40 C to +85 C ( 40 F to +185 F) 5% to 95% (without condensation) CE marked for all applicable directives
A 2 Module Specifications Notes:
The following data define extend and retract profiles for the sample program: Extend position setpoints #N7:0 Extend voltage values #N7:10 Retract position setpoints #N7:20 Retract voltage values #N7:30 This ladder program loads profiles into the module through the output image table. (The 1746-QV module is in slot 1 for this example.) Rung 2.0 Program Profile S:1 N7:40 ] [ È (L) + 15 0 Rung 2:1 Set to Extend Positions Voltages program profile stored stored profile complete Extend Position Setpts. N7:40 N7:8 I:1.0 I:1.0 +COP + ] [ ]/[ ]/[ ]/[ +COPY FILE + 0 0 13 14 Source #N7:0 Dest #O:1.0 Length 8 + + Rung 2:2 Set to Extend Positions Voltages program profile stored stored profile complete Extend Velocity Setpts. N7:40 N7:8 I:1.0 I:1.0 +COP + ] [ ]/[ ] [ ]/[ +COPY FILE + 0 0 13 14 Source #N7:10 Dest #O:1.0 Length 8 + + Rung 2:3 Set to Extend Run/store Positions Voltages Extend program profile retract stored stored profile profile complete complete N7:40 N7:8 I:1.0 I:1.0 I:1.0 N7:8 ] [ ]/[ ]/[ ]/[ ] [ È + (L) + 0 0 12 13 14 0 Program extend voltages O:1.0 + (U) + 6 Rung 2:4 Set to Extend Positions Voltages program profile stored stored profile complete Retract Position Setpts. N7:40 N7:8 I:1.0 I:1.0 +COP + ] [ ] [ ]/[ ]/[ +COPY FILE + 0 0 13 14 Source #N7:20 Dest #O:1.0 Length 8 + +
B 2 Ladder Program Rung 2:5 Set to Extend Run/store Positions Voltages program profile retract stored stored profile complete Retract Velocity Setpts. N7:40 N7:8 I:1.0 I:1.0 I:1.0 +COP + ] [ ] [ ] [ ] [ ]/[ +COPY FILE + 0 0 12 13 14 Source #N7:30 Dest #O:1.0 Length 8 + + Rung 2:6 Set to Extend Run/store Positions Voltages Retract program profile retract stored stored profile profile complete complete N7:40 N7:8 I:1.0 I:1.0 I:1.0 N7:8 ] [ ] [ ] [ ]/[ ] [ È + (L) + 0 0 12 13 14 1 Program retract voltages O:1.0 + (U) + 8 Rung 2:7 Set to Extend Retract Loading program profile profile profiles profile complete complete complete N7:40 N7:8 N7:8 N7:40 ] [ ] [ ] [ È + (U) + 0 0 1 0 Extend Profile Complete N7:8 + (U) + 0 Retract Profile Complete N7:8 + (U) + Rung 2:8 1 Set to program profile N7:40 +COP + ]/[ È+ +COPY FILE + + 0 Source #I:1.0 Dest #N7:60 Length 8 + + +MOV + + +MOVE FILE + + Source N7:50 0 Dest O:1.0 0 + + Rung 2:9 +END+ È + Extend Positions Extend Voltages Retract Positions Retract Voltages G-file for Module Configuration Address Data (radix = DECIMAL) #N7:0 32 45 50 200 300 400 425 500 0 0 #N7:10 64 3000 3750 4000 4000 4000 4000 4000 0 0 #N7:20 128 45 50 200 300 400 425 500 0 0 #N7:30 256 5000 6000 6000 3000 1000 50 25 0 0 G1:0 2056 890 640 12 1200 32,768 0 SLC Code for QV Module LDT Calibration Length Counts Config Word 5 bit 15=1 (position increases toward LDT head) Preset Reference
You use the following files when programming the SLC processor for an application with the 1746-QV module: input image table to indicate status G file to configure the module for its LDT output image table for commands and loading profiles Input Image Table Word 0 (I:e.0 or N7:60 in the ladder program) reports status such as hardware faults, your data-entry errors, and acknowledgement of profile data stored in the module. Word 1 reports position data. Words 2-7 report speeds of the previous profile. Word #: Bit #: Description: (for error & fault bits 0-8, status of 0 = OK, status of 1 = fault.) 0 0 The module sets this LDT error bit when it detects a: broken or mis-wired LDT cable faulty LDT incompatible LDT type (DPM or RPM) missing LDT magnet loss of 15V dc PS 1 Module fault, such as EEPROM error. May turn outputs OFF (fault dependent) 2 The module sets this bit when it detects any of the following invalid command bits or bit combinations in output image table word 0 (O:e.0): one or more of the reserved bits 9-15 were set bit 5 or 7 (position) was set concurrently with bit 6 or 8 (voltage) output enable bit 0 (extend) or 1 (retract) was set before loading valid profiles both output enable bits 0 (extend) and 1 (retract) were set concurrently started to run a profile after the module had flagged an LDT error (I:e.0/0) 3 You set one or more of the reserved bits 0-13 in G-file word 5 (Ge:5). 4 You entered an invalid length (word 3) or count (word 4) in the G file. 5 You entered an invalid LDT calibration (words 1 and/or 2) in the G file. 6 You entered a position setpoint outside the range of 32,768 to +32,767 in O:e.1-O:e.7. 7 You entered a voltage value outside the range of 10,000mV in O:e.1-O:e.7. 8 Loss of sensor. The module detected position data (in I:e.1) greater than the LDT length plus the preset reference. Clear this bit by running a profile. 9-11 Reserved. Do NOT use. 12 The module sets this bit after it stores the retract position setpoints or voltage values, or when the retract profile is active. It remains set until another operation is performed. 13 The module sets this bit after it stores your position setpoints. It resets it after you reset the program position bit (O:e.0/5 or O:e.0/7) 14 The module sets this bit after it stores your voltage values. It resets it after you reset the program voltage bit (O:e.0/6 or O:e.0/8) 15 The module sets this bit when it detects the profile is active (output is applied). 1 n/a Position data 2-7 n/a Speed segments 1-6, respectively. The module computes the speed of each segment and reports them in the subsequent profile (reports extend speeds during the next retract profile, etc.)